International comfort products A Series Installation Instructions Manual
Single-stage, 35-in. tall high efficiency, condensing, ultra low nox gas furnace
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INSTALLATION INSTRUCTIONS
High Efficiency, Condensing, Ultra Low NOx Gas Furnace
NOTE: Read the entire instruction manual before starting the installation.
SECTIONS
INTRODUCTION
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ACCESSORIES
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LOCATION
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INSTALLATION
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WINTERIZATION
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PARTS REPLACEMENT GUIDE
Portions of the text and tables are reprinted from NFPA 54/ANSI Z223.1E, with permission of National Fire Protection Association,
Quincy, MA 02269 and American Gas Association, Washington DC 20001. This reprinted material is not the complete and official position
of the NFPA or ANSI on the referenced subject, which is represented only by the standard in its entirety.
Single- -Stage, 35- -in. Tall
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N95ESU
(Series A)
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Filter Size Information
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Opening Dimensions
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Air Delivery CFM
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Hangar Spacing
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Combustion- -Air Vent Pipe, Fitting & Cement Material..
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Maximum Allowable Exposed Vent Lengths Insulation
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Altitude Derate Multiplier for U.S.A.
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Orifice Size and Manifold Pressure
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Blower Off Delay Setup Switch
58
Approved for installations up to 5,400 feet (1646 meters)
62
Use of the AHRI Certified TM Mark indicates a
manufacturer's participation in the program.
For verification of certification for individual
products, go to www.ahridirectory.org .
TABLES
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440 01 4601 01 12/4/2019
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Table of Contents
Related Manuals for International comfort products A Series
Summary of Contents for International comfort products A Series
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Page 1: Table Of Contents
INSTALLATION INSTRUCTIONS Single- -Stage, 35- -in. Tall High Efficiency, Condensing, Ultra Low NOx Gas Furnace N95ESU (Series A) NOTE: Read the entire instruction manual before starting the installation. SECTIONS TABLES Loose Parts Bag ........SAFETY CONSIDERATIONS . - Page 2 Required Notice for Massachusetts Installations IMPORTANT The Commonwealth of Massachusetts requires compliance with regulation 248 CMR as follows: 5.08: Modifications to NFPA- -54, Chapter 10 2) Revise 10.8.3 by adding the following additional requirements: a. For all side wall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above finished grade in the area of the venting, including but not limited to decks and porches, the following requirements shall be satisfied:...
- Page 3 A190253 SHIP WT. FURNACE SIZE BOTTOM INLET CABINET WIDTH OUTLET WIDTH AIR INTAKE LB (KG) WIDTH 0601716 17--- 1/2 (445) 15--- 7/8 (403) 16 (406) 8--- 3/4 (222) 149.4 (67.8) 0802120 21 (533) 19--- 3/8 (492) 19--- 1/2 (495) 10--- 1/2 (267) 167.4 (75.9) 1002120 21 (533)
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Page 4: Safety Considerations
SAFETY CONSIDERATIONS residential construction practices. We require these instructions as a minimum for a safe installation. WARNING Follow all safety codes. Wear safety glasses, protective clothing, and work gloves. Have a fire extinguisher available. Read these instructions thoroughly and follow all warnings or cautions FIRE, EXPLOSION, ELECTRICAL SHOCK, AND included in literature and attached to the unit. -
Page 5: Loose Parts Bag
Table 1 – Minimum Clearances to Combustible Materials for These furnaces are not approved for installation in recreational vehicles outdoors, or in manufactured/mobile homes. When All Units installed on a wood floor, the furnace must be installed on a POSITION CLEARANCE factory- -supplied accessory combustible floor base or evaporator REAR... -
Page 6: Codes And Standards
CODES AND STANDARDS Follow all national and local codes and standards in addition to these instructions. The installation must comply with regulations of the serving gas supplier, local building, heating, plumbing, and other codes. In absence of local codes, the installation must comply with the national codes listed below and all authorities having jurisdiction. -
Page 7: Electrostatic Discharge (Esd) Precautions
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS PROCEDURE CAUTION FURNACE RELIABILITY HAZARD Failure to follow this caution may result in unit component damage. Electrostatic discharge can affect electronic components. Take precautions during furnace installation and servicing to protect the furnace electronic control. Precautions will prevent electrostatic discharges from personnel and hand tools which are held during the procedure. -
Page 8: Air For Combustion And Ventilation
exchangers. When installed parallel with the furnace, dampers or WARNING other flow control must prevent chilled air from entering the furnace. If the dampers are manually operated, they must be CARBON MONOXIDE POISONING / COMPONENT equipped with means to prevent operation of either unit unless the DAMAGE HAZARD damper is in the full- -heat or full- -cool position. - Page 9 WARNING WARNING CARBON MONOXIDE POISONING HAZARD CARBON MONOXIDE POISONING HAZARD Failure to follow this warning could result in personal Failure to follow this warning could result in personal injury or death. injury or death. The operation of exhaust fans, kitchen ventilation fans, Many homes require air to be supplied from outdoors clothes dryers, attic exhaust fans or fireplaces could create a for furnace combustion, ventilation, and dilution of flue...
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Page 10: Minimum Free Area Required
municating spaces if connected by one or more permanent c. Other openings are caulked or sealed. These include joints openings in doors or floors having free area of at least 2 around window and door frames, between sole plates and /1,000 Btuh (4,400 mm /kW) of total input rating of floors, between wall- -ceiling joints, between wall panels,... -
Page 11: Condensate Drain
NOTICE The condensate trap extends below the underside of the casing in the horizontal position. A minimum of 15- -in. of clearance is required between the casing side and the furnace platform for the trap to extend out of the casing in the horizontal position. - Page 12 OPEN STANDPIPE (OPTIONAL WHEN COIL DRAIN IS NOT CONNECTED TO FURNACE DRAIN.) FLOAT SWITCH MUST BE PLUMBED IN THE FACTORY SUPPLIED LOCATION. DO NOT CHANGE THE FACTORY SUPPLIED LOCATION OF THE FURNACE FACTORY CONDENSATE DRAIN. SUPPLIED CONDENSATE FLOAT SWITCH COIL CONDENSATE DRAIN SHOULD NOT CONNECT DIRECTLY TO THE FACTORY SUPPLIED FURNACE...
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Page 13: Condensate Trap
Table 5 – Condensate Trap Bag Contents INSTALLATION CONFIGURATION DESCRIPTION QUANTITY HORIZONTAL UPFLOW UPFLOW OFFSET Trap Assembly Switch with Float Plastic Collar Collar Gasket Screws Rubber Elbow Clamp --- Worm Drive Tube A (.5--- in. x 2.75--- in.) Tube B (.5--- in. x 2.25--- in.) Tube C (.5--- in. - Page 14 Plastic Collar CVPC & Gasket Elbows Tube A Tube 2 A190323 Fig. 15 - - Example of Hose Clamp Installation Upflow Drain Trap Assy Bracket 6. If trap comes unassembled, the components will require assembly (Fig. 19) with PVC glue. After assembly, firmly press the Float Switch into the Trap Assembly.
- Page 15 Horizontal Specific Steps CAUTION 1. Install and tighten remaining two (2) clamps and two (2) long CPVC tubes (Fig. 15 and Fig. 21). Torque the clamps FURNACE OPERATION HAZARD to hand- -tight (15 lb- -in.). Over tightening hose clamps may Failure to follow this caution may result in furnace damage.
- Page 16 It is permissible to run the trap up to 5 ft. away from the furnace to an area with the required trap clearance provided the following steps and conditions are followed. Alternate Horizontal Option - - Remote Trap Installation Specific Steps 1.
- Page 17 Table 6 – Evaporator Coil Spacer or Shield Requirements. NOTE: The metal shield in the figure above is only recommended for use with furnace manufacturer’s A- -Coil and may not be Install Flush to Install with Install with Type of Coil compatible with 3 party coils.
- Page 18 Connect supply- -air duct to flanges on furnace supply- -air outlet. casing. Bypass humidifier may be attached into unused return air Bend flange upward to 90_ with wide duct pliers (Fig. 27). The side of the furnace casing (Fig. 30 and Fig. 31). supply- -air duct must be connected to ONLY the furnace Bottom Return Air Inlet...
- Page 19 Horizontal Installation Suspended Furnace Support The furnace must be supported under the entire length of the NOTE: The furnace must be pitched forward for proper furnace with threaded rod and angle iron (Fig. 33). Secure angle condensate drainage (Fig. 29). iron to bottom of furnace as shown.
- Page 20 Supply Air Connections For a furnace not equipped with a cooling coil, the outlet duct shall be provided with a removable access panel. This opening shall be accessible when the furnace is installed and shall be of such a size that the heat exchanger can be viewed for possible openings using light assistance or a probe can be inserted for sampling the air stream.
- Page 21 Filter Arrangement Filter and Return Duct Sizing Pressure drop must be taken into account when sizing filters, filter WARNING racks, IAQ devices, and associated system ductwork. For a comparison of Pressure Drop (initial/clean resistance to airflow) versus Airflow for a variety of filter media types and sizes (Table FIRE, CARBON MONOXIDE AND POISONING 9).
- Page 22 Table 9 – Filter Media Pressure Drop (Clean) Versus Airflow - - In. W.C. (Pa) Representative After-Market Filter Media* Factory-Accy Fiberglass* Pleated* 16x 25 Filter Washable (1-in. / 2.5 cm) (1-in. / 2.5 cm) (2-in. / 5 cm) (1-in. / 2.5 cm) (2-in.
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Page 23: Air Ducts
AIR DUCTS GAS PIPING NOTICE WARNING FIRE OR EXPLOSION HAZARD Many states, provinces and localities are considering or have implemented standards and/or restrictions on duct sizing Failure to follow this warning could result in personal practices, ductwork leakage, and/or ductwork thermal, airflow injury, death, and/or property damage. -
Page 24: Maximum Capacity Of Pipe
Table 12 – Maximum Capacity of Pipe WARNING NOMINAL LENGTH OF PIPE --- FT (M) IRON PIPE SIZE FIRE OR EXPLOSION HAZARD (3.0) (6.0) (9.1) (12.1) (15.2) IN. (MM) 1/2 (13) A failure to follow this warning could result in personal injury, death, and/or property damage. -
Page 25: Electrical Connections
ELECTRICAL CONNECTIONS 115- -V Wiring Furnace must have a 115-v power supply properly connected and WARNING grounded. NOTE: Proper polarity must be maintained for 115-v wiring. If polarity is incorrect, control LED status indicator light will flash ELECTRICAL SHOCK, FIRE OR EXPLOSION rapidly and furnace will NOT operate. - Page 26 GROUND NEUTRAL LINE VOLTAGE A190263 ELECTRIC DISCONNECT SWITCH COPPER WIRE ONLY ALUMINUM WIRE A11146 Fig. 39 - - Field- -Supplied External Electrical Box on Furnace A190264 Casing Fig. 38 - - Installing J- -Box (When Used) 6. Route field power wiring into external electrical box. External Electrical Box on Furnace Casing 7.
- Page 27 24- -V Wiring 9. Connect field power and neutral leads to furnace power leads inside the external electrical box (Fig. 34). Make field 24- -v connections at the 24- -v terminal strip. (Fig. 41) Power Cord Installation in Furnace J- - Box Connect terminal Y (Fig.
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Page 28: Electrical Data
Representative drawing only, some models may vary. A180241 Fig. 40 - - Typical Single- -Stage Wiring Diagram Fig. 41 - - Example of Single Stage Furnace Control Table 13 – Electrical Data MINIMUM MAXIMUM MAXIMUM OPERATING VOLTAGE VOLTS--- MAXIMUM UNIT WIRE WIRE FUSE OR CKT... - Page 29 VENTING General If this furnace replaces a furnace that was connected to a vent WARNING system or chimney, the vent or vent connectors of other remaining appliances may need to be re- -sized. Vent systems or vent connectors of other appliances must be sized to the minimum size CARBON MONOXIDE POISONING HAZARD as determined using appropriate table found in the current edition Failure to follow the steps outlined below for each appliance...
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Page 30: Vent Termination Kit For Direct Vent (2- -Pipe) System
Table 14 – Vent Termination Kit for Direct Vent (2- -pipe) Systems Approved Two- Pipe Termination Fittings Vent and Allowable 1 1/2--in. 2--in. 2 1/2--in. 3--in. 4--in. Combustion Air Concentric Vent (38 mm) (51 mm) (64 mm) (76--mm) (102 mm) Pipe Diameters 1 1/2--in. - Page 31 Non-Direct Vent / 1-Pipe System NOTICE The vent pipe for a Non Direct Vent (1- -pipe) system must terminate outdoors. References to vent clearances required by RECOMMENDED SUPPORT FOR National Code authorities (Fig. 55). Allowable vent terminations VENT TERMINATIONS (Fig. 57). It is recommended that sidewall vent terminations in excess of A combustion air inlet pipe to the outdoors is not required for a 24 inches (0.6 M) or rooftop terminations in excess of 36...
- Page 32 Representative drawing only, some models may vary in appearance. A190290 NOTE: Do NOT alter the location of the factory- -provided float switch on the furnace condensate trap assembly. NOTE: Only connect combustion air inlet moisture drain downstream of the furnace trap assembly as shown. Dry Well Dry Well Dry Well...
- Page 33 recommended as trace amounts of moisture will evaporate into the 3. For each pipe, multiply the number of elbows by the equi- intake air stream. If the combustion air inlet is located near a valent length for the type of elbow used. Record the equi- moisture exhaust duct, or there are other concerns of excessive valent length of all the elbows for each pipe.
- Page 34 NOTE: Pipe length (ft. / M) specified for maximum pipe lengths one knockout for the vent pipe and the other knockout for the combustion air connection (Fig. 12). located in unconditioned spaces cannot exceed total allowable pipe length as calculated (Table 18). Use a flat blade screwdriver and tap on the knockout on opposite sides, where the knockout meets the casing.
- Page 35 1. Working from furnace to outside, cut pipe to required length(s). 2. De- -burr inside and outside of pipe. 3. Chamfer outside edge of pipe for better distribution of primer and cement. 4. Complete the vent and combustion air pipe installation by connecting the concentric vent or by installing the required termination elbows (Fig.
- Page 36 Table 15 – Hanger Spacing Material Diameter PVC Sch 40 SDR 21 & 26 CPVC Polypropylene 1 1/2--- in. 3--- ft. 2 1/2--- ft. 3--- ft. 3--- ft. 3.25--- ft. 38--- mm 914--- mm 762--- mm 914--- mm 914--- mm 1000 mm 2--- in.
- Page 37 Installing the Vent Termination NOTE: Do not allow insulation or other materials to accumulate inside of pipe assembly when installing it through hole. Roof Terminations 4. Locate assembly through sidewall with rain shield posi- A roof termination of any type will require a 4-in. (102 mm) tioned no more than 1- -in.
- Page 38 Any other unused knockout may be used for combustion air connection. Rotate vent elbow to required position. & Representative drawing only, some models may vary. UPFLOW LEFT CONFIGURATION A11309A Representative drawing only, some models may vary. HORIZONTAL LEFT ---VERTICAL VENT CONFIGURATION A11327A Alternate combustion air connection.
- Page 39 ALTERNATE COMBUSTION AIR CONNECTIONS ALTERNATE COMBUSTION AIR CONNECTIONS Representative drawing only, some models may vary. HORIZONTAL RIGHT ---VERTICAL VENT CONFIGURATION A11337 Representative drawing only, some models may vary. HORIZONTAL RIGHT ---RIGHT VENT CONFIGURATION A11335 Fig. 52 - - Horizontal Right (Appearance may vary) See “Notes for Venting Options”...
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Page 40: Deductions From Maximum Equivalent Vent Length
Table 17 – Maximum Allowable Exposed Vent Length in Unconditioned Space - - Ft. Unit Size 60,000 BTUH Uninsulated 3/8-in. Insulation 1/2-in. Insulation Pipe Dia. in. 1 ½ 2 ½ 1 ½ 2 ½ 1 ½ 2 ½ Winter Design Temp °... -
Page 41: Venting
Venting System Length Calculations The Total Equivalent Vent Length (TEVL) for EACH combustion air or vent pipe equals the length of the venting system, plus the equivalent length of elbows used in the venting system (Table 19). Standard vent terminations or factory accessory concentric vent terminations count for zero deduction. See vent system manufacturer’s data for equivalent lengths of flexible vent pipe or other termination systems. - Page 42 A190032 Fig. 53 - - Inside Corner Termination Inside Corner Terminations Inside corner vent terminations are permitted provided that: S Only two exterior walls come together to form an angle of 90 degrees to 135 degrees. There are no other exterior walls attached to either wall to form an alcove.
- Page 43 A12326 Fig. 54 - - Direct Vent Termination Clearance NOTE: The following is based upon National codes for gas appliances and is provided as a reference. Refer to local codes which may supersede these standards and/or recommendations. (1 ) (2 ) Canadian Installations U.S.
- Page 44 A12325 Fig. 55 - - Ventilated Combustion Air and Non- -Direct Vent Termination Clearance NOTE: The following is based upon National codes for gas appliances and is provided as a reference. Refer to local codes which may supersede these standards and/or recommendations. (1 ) (2 ) Canadian Installations...
- Page 45 ¾ in. (222mm) for 3 in. (76mm) ¾ in. (172mm) for 2 in. (51mm) 12 in. (305mm) min. separation between bottom of combustion air and bottom of vent (Typ.) A13305 Fig. 56 - - Combustion Air and Vent Pipe Termination for Direct Vent (2- -Pipe) System Roof Termination (Preferred) Vent Maintain 12 in...
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Page 46: Start- -Up, Adjustment, And Safety Check
Ventilated Combustion Air intake pipe Pipe hangar 3” (76 mm) 12” (305 mm) Ventilated Combustion Air intake termination in crawl space CRAWL SPACE highest level of insulation ATTIC A10497 Fig. 58 - - Vent Terminations for Ventilated Combustion Air START- -UP, ADJUSTMENT, AND SAFETY 1. - Page 47 4. Verify furnace restarts by raising thermostat setting above CAUTION room temperature. Prime Condensate Trap with Water FURNACE DAMAGE HAZARD Failure to follow this caution may result in reduced furnace CAUTION life. DO NOT redrill orifices. Improper drilling (burrs, out- -of- -round holes, etc.) can cause excessive burner noise UNIT OPERATION HAZARD and misdirection of inlet gas.
- Page 48 k. Turn gas supply manual shutoff valve to OFF position. 5. Verify natural gas input rate by clocking meter. NOTE: Gas valve regulator adjustment cap must be in place for l. Turn off furnace power supply. proper input to be clocked. m.
- Page 49 NOTE: If the temperature rise is outside this range, first check: (3.) Record amp. draw across terminals when furnace is in heating and after blower starts. (3.) Gas input for heating operation. (4.) Set heat anticipator on thermostat per thermostat in- (4.) Return and supply ducts for excessive restrictions structions and install on subbase or wall.
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Page 50: Gas Rate
Table 22 – Gas Valve Outlet Pressure for Gas Heat Values at 5. Verify that the Status LED glows. If not, check that the power supply is energized and that the blower door is Altitude - - 60,000 secure. Interpret diagnostic codes (Fig. 63). 6. -
Page 51: Service And Maintenance Procedures
Table 23 – Gas Valve Outlet Pressure for Gas Heat Values at Table 24 – Gas Valve Outlet Pressure for Gas Heat Values at Altitude - - 80,000 Altitude - - 100,000 (Tabulated Data Based on 100,000 BTUH Input for 0-ft (0m) to (Tabulated Data Based on 80,000 BTUH Input for 0-ft (0m) to 5400-ft (1646 M) above sea level) 5400-ft (1646 M) above sea level) - Page 52 General Electrical Controls and Wiring These instructions are written as if the furnace is installed in an WARNING upflow application. An upflow furnace application is where the blower is located below the combustion and controls section of the furnace, and conditioned air is discharged upward. Since this ELECTRICAL OPERATION HAZARD furnace can be installed in any of the 3 positions (Fig.
- Page 53 A190255 Fig. 63 - - Service Label Information Component Self-Test Care and Maintenance The control must be powered and the thermostat satisfied (no call WARNING for heat or cool). Depress and hold the SW1 button for at least 10 seconds (but not more than 15 seconds), until the LED is blinking in AMBER, then release.
- Page 54 frequency of maintenance and the availability of a maintenance WARNING contract. WARNING ELECTRICAL SHOCK, FIRE OR EXPLOSION HAZARD Failure to follow this warning could result in personal ELECTRICAL SHOCK AND FIRE HAZARD injury or death, or property damage. Failure to follow this warning could result in personal injury, Before installing, modifying, or servicing system, main death, and/or property damage.
- Page 55 7. If a greasy residue is present on blower wheel, remove 17. Cycle furnace through one complete heating and cooling cycle. Verify the furnace temperature rise as shown in “Ad- wheel from the blower housing and wash it with an appro- justments”...
- Page 56 d. Clean the flame sensor with fine steel wool (0000 grade). WARNING Do not use sand paper or emery cloth. e. If replacement is required, remove the screw that secures the flame sensor on the bracket and remove the flame ELECTRICAL OPERATION HAZARD sensor.
- Page 57 8. Turn on gas and electrical supplies to furnace. not practical to verify the actual heating of the tape. Check the following: 9. Verify igniter operation by initiating control board self- -test feature. Run the furnace through two complete heating cy- 1.
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Page 58: Sequence Of Operation
6. Carefully remove burner insulation assembly, Insulation Since the furnace uses a condensing heat exchanger, some water MUST be replaced before reassembly. will accumulate in the unit as a result of the heat transfer process. Therefore, once it has been operated, it cannot be turned off and 7. - Page 59 d. Trial for Ignition: Once the igniter warm- -up period has on the COOL speed for the duration of the Cool Blower expired, the control sets the inducer to the “Trial for Off-Delay timing (fixed 90 seconds). Ignition” setting and stabilizes the inducer speed to meet OFF: The controls returns to the stand- -by mode until either a the target pressure.
- Page 60 345157--- 2 REV C A190254 Fig. 68 - - Wiring Diagram 440 01 4601 01 Specifications subject to change without notice.
- Page 61 Line voltage (115VAC) polarity reversed. RAPID FLASHING (GREEN) Error history was successfully cleared EACH OF THE FOLLOWING STATUS CODES IS A COMBINATION OF A SERIES OF FLASHES WITH A SPECIFIC COLOR LED COMPONENT TEST LED ACTIVITY (CFH = Call for Heat) 1 FLASH (RED) System Lockout: Retries Exceeded, 1 Lock Out..
- Page 62 The qualified installer or service agency must use only factory- -authorized replacement parts, kits, or accessories when modifying this product. Copyright 2019 International Comfort Products Lewisburg, TN 37091 USA 440 01 4601 01 Specifications subject to change without notice.
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